Manufacturing process and apparatus having an interchangeable machine tool head with integrated control

ABSTRACT

A modular manufacturing system and methods of using are provided. The modular manufacturing system includes a plurality of manufacturing heads that perform different manufacturing processes. These heads may include multi-axial machining heads, fiber placement heads including fiber tow and fiber tape lay-up heads. The heads are fixably attachable to a single positioning system that can manipulate the various heads along a plurality of different degrees of freedom relative to a tool or material blank.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a Continuation of co-pending U.S. patentapplication Ser. No. 13/198,788 filed Aug. 5, 2011, which claims thebenefit of U.S. Provisional Patent Application No. 61/371,236, filedAug. 6, 2010, and U.S. Provisional Patent Application No. 61/406,192,filed Oct. 25, 2010, the entire teachings and disclosures of which areincorporated herein by reference thereto.

FIELD OF THE INVENTION

This invention generally relates to machine apparatuses and particularlydevices for the purposes of multi-axial metal removal, such as cuttingmachine tools, and composite fiber tape manufacturing or composite fiberplacement manufacturing.

BACKGROUND OF THE INVENTION

The practice of manufacturing in aircraft or aerospace fields has becomesimultaneously complex and diverse requiring multiple disciplinesincorporating either metal removal in the form of cutting the desiredpiece from a larger general shape of the desired metal, or theapplication of composite fiber in broad bands commonly referred to as“tape” against a stationary tool, mold or rotating mandrel (referred togenerically herein as a tool), or the application of smaller compositefiber “tows” against a tool.

Each of these methods of manufacturing has been dependent upon theincorporation and utilization of Computer Aided Design and Manufacturing(“CAD/CAM”) software programs which identify and premise allmanufacturing processes through a series of algorithms executed from amain computer through the appropriate machine tool software. Thesealgorithms include certain formula known specifically to the machinetool in regards to positions, pressure application against the mold,tool, rate of speed of movement across a predetermined pathway, rate ofspeed of rotation for the purposes of cutting or removing metal from apre-designated area, ranges of drill or bore depth, and a myriad ofother movements or functions necessary to complete the desired finishedproduct.

The practice in the respective industrial applications has been thedevelopment of custom made machine systems singularly dedicated to theidentified manufacturing process (i.e. machines specifically formulti-axial metal removal, or machines specifically for composite tapeapplication, or machines specifically for composite fiber towapplication), without opportunity for diversified utilization in otherapplications. Such specialization has limited manufacturers in theirability to secure business by reason of the considerable financialcommitment necessary to acquire an efficient, contemporary,comprehensive manufacturing machine and its attendant software. This isdue to redundant costs for redundant portions of the various systemsthat are generally universal to all processes.

As a result of this specialization, many manufacturers having limitedfinancial resources have been unable to expand their enterprise in otherfields or have been limited in either capacity or competitive ability,to engage in other types of manufacturing as related to the aircraft oraerospace industries.

What is needed therefore, is a manufacturing system that provides atraditional base positioning system, such as a gantry having a ram ineither a vertical or horizontal presentation in relation to the toolthat also provides a means by which the system may accommodate either amulti-axial metal removal machine tool head, a composite tape lay-uphead or a composite fiber tow head for application and compactionagainst the fixed tool.

The invention provides such a multiple application machine tool headsystem and apparatus. These and other advantages of the invention, aswell as additional inventive features, will be apparent from thedescription of the invention provided herein.

BRIEF SUMMARY OF THE INVENTION

In one aspect, this invention provides a plurality of manufacturingheads having different operating characteristics (e.g. a machine toolhead for multi-axial metal removal, a composite tape lay-up head or acomposite fiber tow head), attachable to a positioning system. Thepositioning system may provide for a plurality of degrees of freedom formoving the particular manufacturing head that is being utilized.Typically, at least three degrees of freedom are provided, but moredegrees of freedom may be provided. Further, the degrees of freedom maybe linear along a straight axis or rotational about a rotational axis(also referred to as a polar axis or polar degree of freedom).

In one embodiment, the position system includes a gantry system thatprovides three degrees of freedom. The gantry system includes ahorizontal or vertical ram for movement along at least one of thedegrees of freedom. The ram attaches to the desired manufacturing head.The positioning system being controlled to move the head and having thecapacity to execute any number of programmed movements in concert with aCAD/CAM program for a CNC product manufacturing process. Those movementsbeing necessary to facilitate the functioning of the manufacturing headrelative to the tool.

Typically, a machine tool head for metal material removal, can includeat least one head. The ram can provide movement in response to theCAD/CAM machine code for CNC product manufacturing along at least twopolar axes in relation to both the gantry and the machine tool piece.

A releasable coupling is provided in the system for removably attachingthe individual manufacturing heads to the positioning system. Oneportion of the coupling is provided by the positioning system. Each ofthe various manufacturing heads includes a mating or cooperating portionof the coupling.

As such, in some embodiments, a manufacturing system allows forefficient interchange of different types of manufacturing heads in theform of either the multi-axial metal removal head, composite tape lay-uphead or composite fiber tow head, by means of a distinctive couplingdevice integrated into the machine tool, composite tape or compositefiber head(s).

In one embodiment, a fully interchangeable manufacturing system for thepurposes of either multi-axial metal removal, composite tape lay-up orcomposite fiber application and compaction, against either a fixed orstationary tool or mold, or a rotating or moveable mandrel is provided.The interchangeable head(s) being manipulated by the positioning systemhaving a base structure that may or may not be considered part of agantry that presents the machine tool head in relation to the tool, moldor mandrel, from either a vertical or horizontal ram assembly attachedto the base structure or gantry.

In another aspect, the invention provides manufacturing system with aplurality of manufacturing heads, each of which are connectable to apositioning system. According to this aspect, each one of the pluralityof manufacturing heads advantageously incorporates a head controller.The positioning system also has a positioning system controller. Thehead controller of each one of the plurality of manufacturing heads canreceive inputs generated manually or from the CAD/CAM software to governthe operation of a particular machining head. The head controller isalso operable to send head-specific position commands to the positioningsystem controller to ultimately effectuate the movement and operation ofthe machining head.

In one embodiment, a manufacturing system according to this aspectincludes a gantry apparatus having functional elements enabling multiplemovement pathways of the gantry, comprising at least three linear axesby means of either two horizontal and one vertical axes of movement, ortwo vertical and one horizontal axes. A moving ram is positioned on oneof the three axes of the gantry movement system. The manufacturingsystem also includes an internal position controller bearing a computernumeric control software oriented processor for determining the range,frequency and depth of movement of the ram device, as directed by asecond corresponding internal position controller having a dedicatedcomputer numeric controlled software program as designed for amanufacturing head.

In another embodiment according to this aspect, a manufacturing systemis provided. The manufacturing system includes a positioning system. Apositioning system controller operably communicates with the positioningsystem to control the movement of the positioning system. Themanufacturing system also includes a plurality of manufacturing headshaving different characteristics. Each one of the plurality ofmanufacturing heads includes and operably communicates with a headcontroller. The head controller is operable to govern the operation ofthe manufacturing head communicating with the head controller. The headcontroller is operable to send position commands to the positioningsystem controller.

Other aspects, objectives and advantages of the invention will becomemore apparent from the following detailed description when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification illustrate several aspects of the present invention and,together with the description, serve to explain the principles of theinvention. In the drawings:

FIG. 1 is a perspective illustration of a modular manufacturing systemaccording to an embodiment of the present invention having a pluralityof manufacturing heads, with a multi-axial machine tool head attached toa positing system thereof;

FIGS. 2-4 is an illustration of the system of FIG. 1 with a compositefiber tow placement apparatus, having a self contained creel assembly,attached to the positioning system thereof;

FIG. 5 is an illustration of the system of FIG. 1 with a composite fibertape placement head attached to the positioning system thereof;

FIG. 6 is an illustration of the interchangeable composite tapeplacement head of FIG. 1 illustrating a portion of the coupling forfixably attaching the manufacturing head to the positioning system; and

FIG. 7 is a schematic illustration of one embodiment of a controlarrangement of the system of FIG. 1.

While the invention will be described in connection with certainpreferred embodiments, there is no intent to limit it to thoseembodiments. On the contrary, the intent is to cover all alternatives,modifications and equivalents as included within the spirit and scope ofthe invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a modular manufacturing apparatus 100 (also referredto as a “modular manufacturing system”) according to an embodiment ofthe present invention. The modular manufacturing apparatus 100 can beused for various manufacturing processes including cutting or millingoperations, as well as composite fiber placement operations (includingboth fiber tape and fiber tow placement onto a stationary tool, mold ormoveable mandrel). The modular manufacturing apparatus 100 isconfigurable to independently perform these various differentmanufacturing processes. However, a majority of the primary structuresof the modular manufacturing apparatus 100 are reusable for thedifferent manufacturing processes such that the capital investment forproviding the devices to perform these various manufacturing processesis significantly reduced.

In FIG. 1, the modular manufacturing apparatus 100 generally includes apositioning system, illustrated in the form of gantry system 102, thatprovides three linear axes of motion illustrated as double-headed arrows104-106. The linear axes of motion 104-106 are preferably perpendicularto one another. To provide motion along axis 104, the gantry system 102generally includes a pair of radially spaced apart linear rails 108, 110that form a base 112 that supports the rest of the structure of thegantry system 102. A horizontal gantry 114 is supported by the parallellinear rails 108, 110. The horizontal gantry 114 is mechanically drivenalong base 112 generally parallel to linear axis 104.

Attached to the horizontal gantry 114 is a vertical ram 116. Thehorizontal gantry 114 provides horizontal movement along linear axis106. This allows the vertical ram 116 to be laterally positionedrelative to linear rails 108, 110 parallel to linear axis 106. Further,the vertical ram 116 provides a linear vertical degree of freedom to thegantry system 102 parallel to the third linear axis 105.

Such a gantry system 102 is extremely expensive and providing such agantry system for a single dedicated head can be wasteful andeconomically prohibitive to a manufacturing company. For instance, whenit is desirable to machine a specific metal component, for example amold, the other gantry systems relating to other processes such as fiberlayup may sit idle. This could be particularly true if the mold is themold upon which the fiber layup devices will operate.

Attached to the vertical ram 116, in FIG. 1, is a multi-axial machininghead 120 for machining a piece of material (i.e. a blank of material).The machining head 120 may be considered an end-effecter in someembodiments. The machining head 120 may be a multi-axial materialremoval tool for removing material from a blank piece of material alongvarious different axes.

The apparatus 100 includes a coupling 122 for mechanically securing themachining head 120 to the vertical ram 116. This coupling allows themachining head 120 to be easily automatically attached to and detachedfrom the vertical ram 116.

Incorporated into the coupling 122 between the machining head 120 andthe vertical ram 116 may be an electrical coupling that operablyconnects the machining head 120 to external electrical sources andcontrol systems. This electrical coupling is not shown in FIG. 1. Thiselectrical coupling could be internal to coupling 122 or may be anexternal independent coupling that does not form part of coupling 122that mechanically secures the machining head 120 to the vertical ram116.

The modular manufacturing apparatus 100 further includes additionalmanufacturing heads, namely a fiber tow layup head 124 as well as afiber tape head 126. In the configuration illustrated in FIG. 1, thefiber tow head 124 and fiber tape head 126 are in a stored position. Thefiber tow head 124 and fiber tape head 126 are mounted on separate racks128, 130. These heads 124, 126 are waiting to be used by the modularmanufacturing apparatus 100 in conjunction with a tool upon which thecomposite fiber tows or tape is laid-up. Each of the heads 120, 124, 126include a portion of coupling 122 and a mating or cooperating portion isprovided on the end of the ram 116.

In FIG. 1, coupling portions 132, 134 of the fiber tow head and fibertape head 124, 126 are illustrated. These coupling portions 132, 134 inaddition to the coupling portion of the multi-axial machining head 120,are substantially identical for mechanically coupling the individualheads 120, 124, 126 to the vertical ram 116. These additional heads 124,126 have a same, a slightly different, or an entirely differentelectrical coupling for coupling the heads 124, 126 to the externalcontrol module 138.

However, due to the inclusion of a generally universal coupling for eachof the various manufacturing heads 120, 124, 126, the individual headscan be easily fixably attached to the vertical ram 116 such that themodular manufacturing apparatus 100 can be configured to perform thedesired manufacturing process, such as for example material milling ormachining, fiber tow layup, or fiber tape layup. However, unlike priorsystems that would require an individual positioning system for movingand other wise controlling each of the heads, such as illustrated asgantry system 102, only a single gantry system 102 is required forperforming the various different manufacturing processes. Thesedifferent processes are performed at different times as only one headcan be attached to the gantry system 102 at a given time.

FIGS. 3-5 illustrate different configurations or orientations of themodular manufacturing apparatus 100 of the present invention. In FIG. 2,the modular manufacturing apparatus 100 is using the fiber tow head 124to dispense fiber tows onto a female stationary mold 140 in thisorientation the previous head, namely milling head 120 is mounted on astationary rack adjacent to rack 128 housing the fiber tape head 126.FIG. 3 is similar to FIG. 2 in that the modular manufacturing apparatus100 is using a fiber tow head 124 to layup fiber tows onto a stationarymold 142. FIG. 4 is the similar orientation or configuration as in FIGS.2 and 3. However, in this embodiment, the fiber tow head 124 is applyingfiber tows to a rotatable mandrel 144 as opposed to a fixed positionmold or tool.

FIG. 5 is an alternative orientation or configuration of the modularmanufacturing apparatus 100. In this configuration, the modularmanufacturing apparatus 100 is configured with a fiber tape head 126attached to vertical ram 116 for placement of fiber tape on mold 146.Again, the fiber tape head 126 is attached to vertical ram 116 using thestandard coupling 134 (see FIG. 1). FIG. 6 is an enlarged illustrationof the fiber tape head 126.

Returning to FIG. 1, the horizontal gantry 114 portion of the gantrysystem 102 has a horizontal portion 160 that extends laterally outwardbeyond rail 108 a sufficient distance such that the vertical ram 116 canbe positioned laterally outward beyond rail 108 and aligned with thevarious racks and various heads 120, 124, 126 supported thereby.However, during operation, the racks and spare heads 120, 124, 126 areout of the way of the gantry system 102 such that the gantry system 102has free movement along the various linear axes 104-106.

The coupling portions discussed previously are substantiallymechanically all identical such that they can be coupled to the verticalram 116. In FIG. 6, coupling 134 illustrates the inclusion of aplurality of vertically extending posts 161-164. These verticals posts161-164 cooperate with corresponding structure of the vertical ram 116to fixably secure the various heads 120, 124, 126 to the vertical ram116.

The fiber placement heads including the fiber tow head 124 and fibertape head 126 may be constructed according to U.S. patent applicationSer. No. 12/696,476 entitled “Fiber Delivery Apparatus and System Havinga Creel and Fiber Placement Head Sans Fiber Redirect,” filed on Jan. 29,2010, assigned to the assignee of the instant application. Therefore,the fiber placement heads 124, 126 may be self contained creelassemblies for housing either fiber tows or fiber tapes of therespective fiber placement heads 124, 126. Further, these heads mayinclude various different degrees of freedom. Typically the degrees offreedom provided by the various heads are rotational degrees of freedomaround axes that are generally perpendicular to one another.

Other manufacturing heads for performing additional manufacturingprocesses could be used with the modular manufacturing apparatus 100.For example, the modular manufacturing apparatus 100 can also include acoordinate measurement machine (CMM) head (not shown) for the inspectionof various dimensions of a workpiece. As another example, a surfacetreatment head (not shown), e.g. painting head, can also be provided. Asyet another example, an ultra-sonic cutting head can also be provided.Indeed, it will be recognized that any number and type of heads can beemployed to achieve the advantages discussed herein. As such, theapparatus 100 is not limited to particular types of manufacturing heads120, 124, 126 discussed herein.

The modular manufacturing apparatus 100 can thus be seen to provide asignificant cost reduction in the number of gantry system 102 requiredfor the various different manufacturing processes. Further, only asingle control module 138 would be required for the individual gantry102. This control module 138 can then be used to control variousdifferent types of manufacturing processes. The control module wouldonly need to be programmed with the particular software for controllingthe different processes. This significantly reduces the cost andoverhead for a manufacturer that wants to or needs to be able to providethese various different types of manufacturing processes in a givenlocation. This also significantly reduces the overall footprint of themanufacturing apparatus significantly reducing the size of a neededbuilding for housing the modular manufacturing apparatus 100.

Additionally, and with reference back to FIG. 2, each of the heads 120,124, 126 may include a stand alone controller 150, 154, 156,respectively. Each of the controllers 150, 154, 156 are independent fromone another and self contained within each head 120, 124, 126. Further,each controller 150, 154, 156 is operable to control various functionsof its related head 120, 124, 126, as well as receive instructions inthe form of numerical control code to facilitate such control.

Indeed, each head controller 150, 154, 156 implements control logic forposition control, as well as head specific parameters such as speed,feed rate, tool offsets, etc. as governed by code supplied to thecontroller 150, 154, 156. Further, additional control parametersspecific to each head 120, 124, 126 are also contemplated. For example,the tow layup head controller 154 may also implement logic relating tothe operation of cutting tows, switching tow types, rewinding a tow,etc.

The coding for each head controller 150, 154, 156 can be generated usingCAD/CAM software at a workstation 200, on or off-site. The coding isthereafter sent from the work station 200 to the control module 138, andthereafter to each of the head controllers 150, 154, 156 whereappropriate. Alternatively, the coding for each head controller 150,154, 156 can be generated manually at the control module 138 of theapparatus 100.

Still referring to FIG. 2, the ram 116 can also incorporate a standalone, independent ram position controller 158. The ram positioncontroller 158 is self contained within the ram 116. The ram controller158 is operable to control various functions related to the ram 116 aswell as receive instructions in the form of numerical control code tofacilitate such control. The ram controller 158 is operable to governthe movement of the ram 116 along axis 105, as well as the gantry 114along axes 102 and 104.

The ram position controller 158 implements control logic for position,speed, feed rate, tool offsets, etc. as governed by code supplied to theram position controller 158. In certain embodiments, the ram controller158 communicates with the head controllers 150, 154, 156 such that oncethe code is generated for the head controllers 150, 154, 156, each sendsa corresponding set of commands to the ram position controller 158.

The above communication between the ram controller 158 and headcontrollers 150, 154, 156 is schematically illustrated in FIG. 7. Codeis generated and sent from an interface 202 which can include thecontrol module 138 and a work station 200. The code specific to eachhead 120, 124, 126 is received by the head controllers 150, 154, 156.Each head controller 150, 154, 156, is operable to generate and sendposition commands to the ram position controller 158 to effectuate themovement of the ram 116 and gantry 114 (see FIG. 1).

As one advantage, each head controller 150, 154, 156 can implement headspecific tool offsets, feed rates, etc. within the position commandssent to the ram controller 158. For example, when a move command is sentto the head controller 150, the head controller 150 can implement headspecific tool offsets prior to sending the resultant move command to theram controller 158 to ultimately effectuate the movement of the head 120relative to a workpiece. Such a configuration advantageously allows forthe accurate control and operation of the ram 116 and gantry 114 despiteusing various machining heads having different operating characteristicsand shape.

Still referring to FIG. 7, the ram position controller 158 can alsoreceive commands directly from the interface 202. Additionally, the headcontrollers 150, 154, 156 and ram controller 158 also operablycommunicate with the interface 202 to provide a feedback loop to ensureaccurate control of the apparatus 100.

Methods of switching between the various heads are provided that includeswitching from one head to another by setting one head on itscorresponding rack and then connecting to the next desired head.

All references, including publications, patent applications, and patentscited herein are hereby incorporated by reference to the same extent asif each reference were individually and specifically indicated to beincorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) is to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

What is claimed is:
 1. A modular manufacturing apparatus comprising: apositioning system; a plurality of manufacturing heads, eachmanufacturing head having a different characteristic; and a couplingarrangement, the positioning system providing one portion of thecoupling arrangement and each of the manufacturing heads having acooperating portion of the coupling arrangement configured to couplewith the portion of the coupling arrangement of the positioning system.2. The modular manufacturing apparatus of claim 1, wherein the pluralityof manufacturing heads includes at least one fiber tow head configuredto lay fiber tows and at least one fiber tape head configured to layfiber tape.
 3. The modular manufacturing apparatus of claim 1, whereineach of the plurality of manufacturing heads includes a head controller,the head controller operable to govern the operation of themanufacturing head.
 4. The modular manufacturing apparatus of claim 3,further comprising a control module, the control module configured tooperably communicate with each of the head controller when thecorresponding manufacturing head is operably attached to the positioningsystem.
 5. The modular manufacturing apparatus of claim 4, wherein thepositioning system further includes a position controller, the positioncontroller being independent from the head controllers, the positioncontroller in operable communication with each head controller when thecorresponding manufacturing head is operably attached to the positioningsystem such that the head controller of the attached manufacturing headcan communicate position commands to the position controller to controlmovement of the positioning system.
 6. The manufacturing system of claim1, wherein the positioning system includes a three axis gantry systemproviding movement along three generally perpendicular axes, the gantrysystem including a pair of base rails for movement along a first axis, ahorizontal gantry for movement along a second axis perpendicular to thefirst axis, the horizontal gantry linearly moveable relative to the pairof base rails along the first axis, a vertical ram for movement along athird axis, the vertical ram linearly moveable along the second axis,the horizontal gantry including a portion extending laterally outwardbeyond the pair of rails in a direction extending parallel to the secondaxis, the vertical ram movable along the portion of the horizontalgantry along the second axis outward beyond the pair of rails; and atleast one rack configured to hold at least one of the manufacturingheads, the at least one rack being positioned laterally outward beyondthe pair of rails and aligned with the portion of the horizontal gantryextending laterally outward beyond the pair of rails such that thepositioning system can selectively connect and disconnect frommanufacturing heads stored on the at least one rack.
 7. The modularmanufacturing apparatus of claim 1, wherein the plurality ofmanufacturing heads includes at least one milling head configured tomachine a blank of material
 8. A manufacturing system comprising; agantry apparatus having functional elements enabling multiple movementalong at least three linear axes; a plurality of manufacturing heads,each manufacturing head having a different characteristic, the pluralityof manufacturing heads includes at least one fiber tow head configuredto lay fiber tows, each manufacturing head having an internalcontroller, the internal controller of each head having a dedicatedcomputer numeric controlled software program designed for the particularmanufacturing head; an internal position controller for the gantryapparatus bearing a computer numeric control software oriented processorfor determining the range, frequency and depth of movement of the gantryapparatus, as directed by the internal controller of any one of theplurality of manufacturing heads attached to the gantry apparatus; andwherein the internal controller of each manufacturing head is capable ofoperating independently from the other internal controllers of the othermanufacturing heads and is self-contained within its correspondingmanufacturing head.
 9. The manufacturing system of claim 8, furthercomprising a control module programmed for controlling a processassociated with the different characteristic of each of the plurality ofmanufacturing heads.
 10. The manufacturing system of claim 9, whereinthe plurality of manufacturing heads includes at least one at least onefiber tape head configured to lay fiber tape and at least one millinghead configured to machine a blank of material; the control moduleprogrammed to control a process of each of the different manufacturingheads.
 11. The manufacturing system of claim 7, wherein eachmanufacturing head has a first portion of a coupling arrangement forconnecting the manufacturing head to a second portion of the couplingarrangement, the second portion of the coupling arrangement is providedby the gantry apparatus, the first portion of the coupling arrangementprovided by each of the manufacturing heads being substantiallymechanically identical.
 12. A manufacturing apparatus comprising: apositioning system incorporating a gantry apparatus having functionalelements enabling movement along at least three linear, and; a movingram device positioned on one of the three axes of the gantry movementsystem including a first portion of a manufacturing head couplingarrangement; a plurality of manufacturing heads, each manufacturing headhaving a different characteristic, the plurality of manufacturing headsincluding a fiber tape placement compaction head and a fiber towplacement compaction device, each manufacturing head including a secondportion of the manufacturing head coupling arrangement configured tocooperate with the first portion to releasably connect the manufacturinghead to the moving ram device, each head including a correspondinginternal controller having a dedicated computer numeric controlledsoftware program designed for the corresponding head, each internalcontroller located on a manufacturing head side of the manufacturinghead coupling arrangement and not on a moving ram device side of themanufacturing head coupling arrangement; and an internal positioncontroller for the positioning system bearing a computer numeric controlsoftware oriented processor for determining the range, frequency anddepth of movement of the moving ram device as directed by the internalcontroller of a corresponding manufacturing head attached to the movingram device.
 13. The manufacturing apparatus of claim 12, wherein theinternal position controller for the positioning system is independentfrom the internal controller of each of the manufacturing heads and ispositioned on the moving ram device side of the manufacturing headcoupling.
 14. The manufacturing apparatus of claim 13, furthercomprising a control module programmed for controlling associated withthe different characteristics of each of the plurality of manufacturingheads, the control module communicating with the internal controller ofa manufacturing head of the plurality of manufacturing heads operablycoupled to the moving ram device, the control module communicating withthe internal position controller.
 15. The manufacturing apparatus ofclaim 12, wherein the second portions of the manufacturing head couplingarrangement of the plurality of manufacturing heads are substantiallymechanically identical.
 16. A manufacturing system, comprising: apositioning system; a plurality of manufacturing heads, eachmanufacturing head having a different characteristic; wherein each oneof the plurality of manufacturing heads includes a head controller, thehead controller operable to govern the operation of the correspondingmanufacturing head; wherein the positioning system includes a three axisgantry system providing movement along three generally perpendicularaxes, the gantry system including a pair of base rails for movementalong a first axis, a horizontal gantry for movement along a second axisperpendicular to the first axis, the horizontal gantry linearly moveablerelative to the pair of base rails along the first axis, a vertical ramfor movement along a third axis, the vertical ram linearly moveablealong the second axis, the horizontal gantry including a portionextending laterally outward beyond the pair of rails in a directionextending parallel to the second axis, the vertical ram movable alongthe portion of the horizontal gantry along the second axis outwardbeyond the pair of rails; and at least one rack configured to hold atleast one of the manufacturing heads, the at least one rack beingpositioned laterally outward beyond the pair of rails and aligned withthe portion of the horizontal gantry extending laterally outward beyondthe pair of rails such that the positioning system can selectivelyconnect and disconnect from manufacturing heads stored on the at leastone rack.
 17. The manufacturing apparatus of claim 16, furthercomprising a positioning system controller operably communicating withthe positioning system to control the movement of the positioningsystem; and wherein the head controller is operable to send positioncommands to the positioning system controller to assist in control ofthe operation of the positioning system based on the operation of thecorresponding manufacturing head.
 18. The manufacturing apparatus ofclaim 16, wherein each manufacturing head has a first portion of acoupling arrangement for connecting the manufacturing head to a secondportion of the coupling arrangement, the second portion of the couplingarrangement is provided by the positioning system, the first portion ofthe coupling arrangement provided by each of the manufacturing headsbeing substantially mechanically identical.